SINGLE-USE CONTAINER COMPRISING A FOOTSTOOL

Description

FIELD OF THE INVENTION

The present invention generally relates to the field of beverage containers. In particular, the present invention is directed to a single-use container comprising a footstool.

BACKGROUND

Beverages such as coffee and tea are being increasingly prepared using single serve brewing capsules. Many product benefits are realized when using such capsules versus multi-serve bulk packaged roast and ground coffee. Capsules offer individual choice, wide availability of variety, fresh-brewed flavor, and preparation convenience. Additionally, ecological benefits are realized when using single serve brewing capsules versus bulk-packaged roast and ground coffee; most importantly, less waste of the coffee itself. Some devices for preparing single serve coffee operate by puncturing a capsule. However, such puncturing process may also puncture a filter contained within a capsule, reducing its effectiveness and the quality of the resulting coffee.

SUMMARY OF THE DISCLOSURE

In an aspect, described herein is a single-use container including a sheet including a rim, a sidewall, and a bottom, a lid affixed to the rim, and a footstool including a filter separating a first compartment from a second compartment, wherein the first compartment is encompassed by the lid, a first segment of the sidewall, and the filter, wherein the second compartment is encompassed by the bottom, a second segment of the sidewall, and the filter, and at least a filter support structure positioned between the filter and the bottom.

In another aspect, described herein is a system including a single-use container including a sheet including a rim, a sidewall, and a bottom, a lid affixed to the rim, and a footstool including a filter separating a first compartment from a second compartment, wherein the first compartment is encompassed by the lid, a first segment of the sidewall, and the filter, wherein the second compartment is encompassed by the bottom, a second segment of the sidewall, and the filter, and at least a filter support structure positioned between the filter and the bottom, and a device configured to puncture, using a first prong, the lid of the single-use container without puncturing the filter, and puncture, using a second prong, the bottom of the single-use container without puncturing the filter.

These and other aspects and features of non-limiting embodiments of the present invention will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the invention in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

FIG. 1 is a is an illustration of a side view of an exemplary embodiment of a single-use container;

FIG. 2 is a is an illustration of a side view of cross-section of an exemplary embodiment of a single-use container; and

FIG. 3 is a is an illustration of a top view of an exemplary embodiment of a single-use container;

FIG. 4A is an illustration of a top and side view of an exemplary embodiment of a footstool; and

FIG. 4B is an illustration of a top and side view of an exemplary embodiment of a supplementary filter support structure.

The drawings are not necessarily to scale and may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.

DETAILED DESCRIPTION

At a high level, aspects of the present disclosure are directed to single-use containers, such as single-use coffee pods. A single-use container may include an aluminum capsule suitable for use in low-pressure beverage-making appliances. A single-use container may include a footstool. A footstool may include a filter and a filter support structure.

Referring now to FIG. 1, a side view of an exemplary embodiment of a single-use container 100 is provided. Single-use container 100 includes a food container. In some embodiments, a food container may include a coffee pod. In some embodiments, a coffee pod may include a single-use coffee pod. As used herein, a “food container” is an object which holds food. As used herein, a “coffee pod” is a food container which holds a product made from coffee beans, a product including coffee beans, or both. As used herein, a food container is a “single-use” food container if the food container is not designed to be re-sealed once opened without external devices or replacement parts. For example, a jar with a screw-on lid in which the lid may be freely screwed off and on is not a single-use food container. In another example, a food container with a lid sealed to the food container using an adhesive in which the lid, once removed, cannot be re-applied is a single-use food container. In another example, a food container with a lid which is designed to be opened by tearing or puncturing the food container or lid such that the food container cannot be re-sealed using the same parts is a single-use food container.

Still referring to FIG. 1, in some embodiments, single-use container 100 includes a food container made using a multi-layer sheet. Multi-layer sheet may include a multi-layer laminate sheet. Multi-layer sheet may include primarily aluminum and/or polypropylene. In some embodiments, multi-layer sheet includes a first side and a second side. Single-use container 100 may be manufactured such that first side is on the outside of single-use container 100 and second side is on the inside of single-use container 100. As described below, second side may also make up a top surface of a food container onto which a lid is attached. In some embodiments, a multi-layer sheet includes, from first side to second side, first lubricant layer, varnish layer, printing ink layer, primer layer, aluminum layer, coextrusion coating, and second lubricant layer. In some embodiments, a single-use container and/or multi-layer sheet may be consistent with any multi-layer sheet disclosed in U.S. patent application Ser. No. 18/634,607 (having attorney docket number 1326-006USU1), filed on Apr. 12, 2024, and titled “SINGLE USE CONTAINERS AND METHODS OF MANUFACTURING,” the entirety of which is hereby incorporated by reference. For example, a multi-layer sheet may include one or more materials described in U.S. patent application Ser. No. 18/634,607 and/or such materials may be layered as described in U.S. patent application Ser. No. 18/634,607. In another example, a single-use container and/or multi-layer sheet may be manufactured as described in U.S. patent application Ser. No. 18/634,607.

Still referring to FIG. 1, in some embodiments, single-use container 100 may be symmetrical about central vertical axis 104. In some embodiments, single-use container 100 may be symmetrical across one or more planes, wherein such planes include central vertical axis 104.

Still referring to FIG. 1, in some embodiments, single-use container 100 may include rim 108. Rim 108 may include a flat top surface. Lid 112 may be affixed to such flat top surface. As used herein, a “flat top surface” of a rim is a surface of a rim which is substantially planar. In some embodiments, a flat top surface of a rim may surround a non-planar portion of single-use container 100. In some embodiments, lid 112 may be affixed to rim 108 using an adhesive. In some embodiments, rim 108 may include a “donut” shape with a diameter of 54±0.3 mm along the outside of rim 108 and/or a diameter of 45±0.3 mm along inside of rim 108. Inside and outside edges of rim 108 may form concentric circles. In some embodiments, an outside of flat top surface may have a diameter of 51±0.3 mm. For example, outside of flat top surface may have a diameter of 51 mm and may have a curved surface such that the outermost diameter is 54 mm. In some embodiments, rim 108 may have a height (as in, a distance from bottom of rim 108 to top of rim 108) of 1.3±0.1 mm. Lid 112 may include a removable material which covers contents of single-use container 100. In some embodiments, lid 112 may be affixed such that it may be punctured by a prong without otherwise ripping and/or becoming detached from rim 108. In some embodiments, lid 112 may be removable. In some embodiments, lid 112 may include a tab for ease of lid 112 removal.

Still referring to FIG. 1, in some embodiments, single-use container 100 may include stacking lip 116 and/or stacking shoulder 120. As used herein, a “stacking lip” is a vertical or approximately vertical circular surface which connects a rim to a stacking shoulder. Stacking lip 116 may include a vertical or approximately vertical circular surface which connects to rim 108 and is positioned below rim 108, as shown in FIG. 1. In some embodiments, stacking lip 116 may have a height of 5.7±0.1 mm. In some embodiments, a height from bottom of stacking lip 116 to top of rim 108 may be 5.8±0.1 mm. As used herein, a “stacking shoulder” is a surface which slopes downward and toward central vertical axis 104 and is connects a stacking lip to a sidewall. Stacking shoulder 120 may include an inward sloping surface (such as a surface which slopes downward and toward central vertical axis 104) positioned below stacking lip 116. In some embodiments, inner edge of stacking shoulder 120 may have a diameter of about 43.68 mm. As used herein with respect to diameters, “about” means ±0.3 mm. Stacking lip 116 and/or stacking shoulder 120 may aid in stacking multiple instances of empty food containers. For example, a stacking shoulder of a first food container may rest on a top of a stacking lip of a second food container. In some embodiments, stacking may allow multiple single-use containers, such as multiple single-use containers without lids and/or food contents, to be transported in a space efficient manner. This may be used to, for example, transport single-use containers to a location where they are to be filled or recycled. In some embodiments, such stacking may be used to transport multiple single-use containers lacking footstools, such as transporting single-use containers during a manufacturing process before footstools have been added.

Still referring to FIG. 1, in some embodiments, single-use container 100 may include sidewall 124. Sidewall 124 may be in a conical frustum shape such that the top of sidewall 124 is wider than the bottom of sidewall 124. Sidewall 124 may be attached to, and positioned below, stacking shoulder 120. Sidewall 124 may curve inwards toward the bottom of sidewall 124. Sidewall 124 may slope inward according to draft angle 128. As used herein, a “draft angle” is a difference between the slope of a sidewall and downward. In some embodiments, draft angle 128 may be at least 0.2, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, 2 degrees, or more. In some embodiments, draft angle 128 may be at most 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5.8, 5.6, 5.4, 5.2, 5, 4.8, 4.6, 4.4, 4.2, 4 degrees or less. In some embodiments, draft angle 128 is at least 1 degree and at most 5 degrees. In some embodiments, a draft angle in this range may ease removal of single-use container 100 from a deep drawing device. In some embodiments, a draft angle in this range may enable stacking of multiple instances of single-use container 100.

Still referring to FIG. 1, in some embodiments, single-use container 100 may include one or more ribs 132. Ribs may include straight, aligned indents in sidewall 124. Ribs may aid a user in gripping single-use container 100. In some embodiments, ribs 132 may be vertical. In some embodiments, single-use container 100 may have 24 vertical ribs. In some embodiments, single-use container 100 may include a portion of sidewall 124 above ribs 132 and/or below ribs 132. In some embodiments, ribs 132 do not extend to the top and/or bottom of sidewall 124. In some embodiments, sidewall 124 may include a plurality of ribs, where ribs alternate between extending outward and inward from sidewall 124.

Still referring to FIG. 1, in some embodiments, single-use container 100 may include bottom 136 and/or bottom cutout 140. Bottom 136 may include a flat surface on which single-use container 100 may rest, parallel to the flat top surface as described above, and bottom cutout 140 may include a concave region at the center of bottom 136. In some embodiments, height of bottom cutout 140 is 0.5±0.1 mm. In some embodiments, filling height of single-use container 100 (as in, vertical distance between bottom 136 and rim 108) is 45±0.3 mm. Single-use container 100 may further include raised bottom 144. As used herein, a “raised bottom” is a section of a bottom of a single-use container which is raised above a bottom cutout. In some embodiments, diameter of bottom cutout 140 is about 27 mm. In some embodiments, diameter of outer edge of bottom 136 is about 32 mm.

Still referring to FIG. 1, in some embodiments, design of single-use container 100 described herein may allow single-use container 100 to withstand typical forces in retail grocery distribution, provide excellent oxygen and moisture barriers for foodstuff preservation, and/or operate correctly within a low pressure beverage making appliance.

Referring now to FIG. 2, a side view cross section of an exemplary embodiment of a single-use container 200 is provided. As shown in FIG. 2, single-use container 200 may include rim 108, lid 112, stacking lip 116, stacking shoulder 120, sidewall 124, bottom 136, and/or raised bottom 144. Single-use container 200 may further include a footstool 204. As used herein, a “footstool” is a structure including a filter and a structure supporting the filter. Footstool 204 may include filter 208 and at least a filter support structure. In some embodiments, at least a filter support structure may include filter support structure 212 and/or screen 216.

Still referring to FIG. 2, single-use container 200 may include filter 208. As used herein, a “filter” is a layer of a material which allows water to pass through and does not allow solid particles of sufficient size to pass through. In some embodiments, single-use container may include first compartment 220 and second compartment 224. Filter 208 may separate first compartment 220 from second compartment 224. First compartment may be encompassed by lid 112, a first segment of sidewall 124 and filter 208. Second compartment may be encompassed by bottom 136, a second segment of sidewall 124 and filter 208. In some embodiments, first compartment 220 may include at least a substance. In some embodiments, at least a substance may include a substance which does not pass through filter 208 in the absence of a liquid such as water. In some embodiments, at least a substance may include a food product, such as, without limitation, coffee grounds, tea leaves, and/or another material which may be mixed with a liquid such as water in order to produce a beverage. In some embodiments, at least a substance stored in first compartment 220 may include coffee, such as coffee grounds. In some embodiments, second compartment 224 does not contain at least a substance. In some embodiments, filter 208 may separate first compartment from second compartment such that at least a substance in first compartment 220 does not enter second compartment 224. A variety of types of filter and/or materials for making a filter may be used. In non-limiting examples, a filter may be constructed from paper, cloth, plastic, and/or metal, such as aluminum. In some embodiments, a filter may be constructed from paper. In some embodiments, a filter does not include plastic. Use of a paper filter and/or a filter which does not include plastic may, in some embodiments, reduce the amount of microplastics in a beverage produced using single-use container 200. In some embodiments, footstool 204 does not include a polymeric material. In some embodiments, a filter may be flavored. For example, a filter may include Delta-9-tetrahydrocannabinol (THC). In some embodiments, filter 208 may be flush with sidewall 124, such that there is no gap for at least a substance to pass from first compartment 220 to second compartment 224. In some embodiments, filter 208 may be adhered to and/or fused with sidewall 124. This may, for example, keep filter 208 in place during transportation and/or close any gaps between filter 208 and sidewall 124 in the case that they are manufactured as separate parts.

Still referring to FIG. 2, single-use container 200 may include at least a filter support structure. At least a filter support structure may include filter support structure 212 and/or screen 216. As used herein, a “filter support structure” is a rigid component which provides structural support for a filter. In some embodiments, filter support structure 212 may be positioned between filter 208 and bottom 136. For example, filter support structure 212 may be positioned between filter 208 and raised bottom 144. In some embodiments, filter support structure may include one or more vertical and/or substantially vertical poles which may connect filter 208 to bottom 136 and/or raised bottom 144. In some embodiments, such connection may be achieved by filter support structure 212 being in contact with filter 208, bottom 136 and/or raised bottom 144. In some embodiments, such connection may be achieved by fixing filter support structure 212 to filter 208, bottom 136 and/or raised bottom 144, such as through use of an adhesive. In some embodiments, filter support structure may include one or more metal poles, such as aluminum poles, which connect filter 208 to bottom 136 and/or raised bottom 144. In some embodiments, single-use container 200 may include a plurality of filter support structures. For example, single-use container 200 may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more filter support structures.

Still referring to FIG. 2, in some embodiments, as described further below, a device may be used to make a beverage using single-use container 200, and this process may include puncturing a hole in bottom 136 and/or raised bottom 144. Filter support structures may be positioned in a different location from where a hole is to be punctured. For example, single-use container 200 may be designed to be compatible with a device which punctures a hole in the center of raised bottom 144. Filter support structures may be positioned off-center of bottom 136 and/or raised bottom 144 so that such a device does not hit filter support structure 212 when puncturing bottom 136 and/or raised bottom 144. In some embodiments, filter support structures may be positioned in a ring around a center of bottom 136 and/or raised bottom 144. Such ring may have a diameter of, as examples, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 32 mm, or a number between such values. In some embodiments, single-use container 200 may include a single filter support structure 212 at a center of raised bottom 144. This may, for example, be used along with a device which punctures bottom 136 and/or raised bottom 144 at a location other than the center.

Still referring to FIG. 2, in some embodiments, at least a filter support structure may include screen 216 positioned between the filter and one or more filter support structures supporting the filter. Such a screen may provide additional support for filter 208. In some embodiments, screen 216 may distribute pressure from filter support structures 212 across screen 216 so that, for example, filter support structures 212 do not puncture filter 208 as single-use container 200 is jostled during transportation. In some embodiments, screen 216 may be constructed from metal, such as aluminum. In some embodiments, screen 216 may be fixed to filter support structure 212, sidewall 124, and/or filter 208, such as through use of an adhesive. In some embodiments, filter 208 and/or screen 216 may be parallel with and/or substantially parallel with lid 112.

Still referring to FIG. 2, in some embodiments, single-use container 200 may be a component of a system including a device used to make a beverage, such as a coffee machine. In some embodiments, such a device may create a beverage by using a first prong 228 to puncture a first hole in lid 112, using a second prong 232 to puncture a second hole in bottom 136, and running a liquid such as water into the first hole and out of the second hole, such that the liquid flows through and/or is infused with at least a substance held in first compartment 220. In this case, filter 208 allows the liquid through the filter, into second compartment 224, and out second hole, while at least a substance in first compartment 220 is prevented from entering second compartment 224 by the filter.

Still referring to FIG. 2, in some embodiments, filter 208, filter support structure 212, and/or screen 216 may be positioned such that they are not impacted and/or pierced by first prong 228 and/or second prong 232 as they puncture the exterior of single-use container 200. In some embodiments, first distance 236 between lid 112 and filter 208 may be longer than first prong 228 and/or a length of first prong 228 which extends into single-use container 200 when first prong 228 punctures lid 112. In some embodiments, second distance 240 between bottom 136 and screen 216 (or between bottom 136 and filter 208 if screen 216 is not present) may be longer than second prong 232 and/or a length of second prong 232 which extends into single-use container 200 when second prong 232 punctures bottom 136. In some embodiments, first distance 236 may be 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, or a number between such values. In some embodiments, second distance 240 may be 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, or a number between such values. In some embodiments, filter support structure 212 may be positioned such that it is not impacted, pierced, and/or otherwise interfered with by first prong 228 and/or second prong 232 as they puncture the exterior of single-use container 200. In a non-limiting example, system 200 may be configured such that second prong 232 pierces the center of bottom 136, and filter support structure 212 may be positioned off-center. In another non-limiting example, system 200 may be configured such that second prong 232 pierces off-center of bottom 136, and filter support structure 212 may be at the center. In some embodiments, first distance 236 and/or second distance 240 may be selected based on factors including distances at which prongs pierce each side of single-use container 200 and an amount of at least a substance to be fit into first compartment 220. In some embodiments, a device for creating a beverage may include a computing device.

Still referring to FIG. 2, in some embodiments, single-use container 200 may stack. In some embodiments, single-use container 200 may stack during a manufacturing process, such as before lid 112 has been applied. For example, single-use container 200 may stack as described in U.S. patent application Ser. No. 18/634,607 in a case where footstool 204 is not present, such as before it is added in a manufacturing process. In another example, once footstool 204 is added, single-use container 200 may stack with a bottom of a first single-use container resting on a footstool of a second single-use container.

Still referring to FIG. 2, in some embodiments, single-use container 200 may be manufactured as described in U.S. patent application Ser. No. 18/634,607. In some embodiments, a manufacturing process may further include an addition of footstool 204, such as by positioning footstool 204 in single-use container 200 and fixing it in place, such as through use of an adhesive. In some embodiments, a manufacturing process may be implemented using a computing device.

Referring now to FIG. 3, a top view of an exemplary embodiment of single-use container 300 is depicted. As shown in FIG. 3, single-use container 300 may include rim 108, stacking lip 116, stacking shoulder 120, sidewall 124, rib 132, bottom 136, raised bottom 144, and/or filter support structure 212. Lid 112 filter 208, and screen 216 are not depicted in FIG. 3. In some embodiments, single-use container 300 may be symmetrical across one or more planes depicted in FIG. 3.

Referring now to FIG. 4A, a top and side view of footstool 400 is depicted. Footstool 400 may include rim 404. Rim 404 may be circular and/or may fit within a single-use container as described herein. Footstool 400 may include filter 408, which may contain a plurality of strands of material positioned so as to prevent objects of sufficient size from passing through. Filter 408 may be affixed to rim 404. Footstool 400 may include filter support structure 412. Filter support structure 412 may include a rigid material positioned beneath and along the outside of rim 404. Filter support structure 412 may contain a corrugated pattern. In some embodiments, a corrugated pattern may improve stability of filter support structure 412 and/or may lower a likelihood that it collapses. Footstool 400 may include a filter support structure bottom 416. In some embodiments, filter support structure bottom 416 may be positioned along an outer rim of a bottom of a single-use container when footstool 400 is inserted into the single-use container.

Referring now to FIG. 4B, a top and side view of a supplementary filter support structure 420 is depicted. Supplementary filter support structure 420 may be positioned beneath a filter and/or footstool such as footstool 400, providing additional support when inside a single-use container. Supplementary filter support structure 420 may include top surface 424, which may include central cutout 428 and/or one or more holes 432. Such central cutout and/or holes may allow material such as liquids to pass through supplementary filter support structure 420. Supplementary filter support structure 420 may further include one or more legs 436, which may include a corrugated rigid material and/or may be supported by one or more leg bottoms 440. Legs 436 may be separated by one or more leg cutouts 444.

The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments, what has been described herein is merely illustrative of the application of the principles of the present invention. Additionally, although particular methods herein may be illustrated and/or described as being performed in a specific order, the ordering is highly variable within ordinary skill to achieve systems and/or containers according to the present disclosure. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.

Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.